System comprising multi-die power module and method for controlling operation of multi-die power module

ABSTRACT

The present invention concerns a system comprising a multi-die power module composed of dies and a controller receiving plural consecutive input patterns for activating the dies of the multi-die power module, wherein the dies are grouped into plural groups of at least one die and in that the controller comprises: —means for outputting one gate to source signal for each group of at least one die, the rising edges and/or falling edges of at least one gate to source signal being iteratively time shifted from the rising edge and/or a falling edge of the other gate to source signals for other groups of dies.

TECHNICAL FIELD

The present invention relates generally to a system and method forcontrolling the operation of a multi-die power module.

BACKGROUND ART

Multi-die power modules are classically composed of several parallelconnected power dies and are used for increasing the current capabilityover that of a single power die.

For example, a three-phase converter can be composed of four parallelpower dies per switch, giving twenty four power dies in total.

Emerging devices technologies, such as SiC (Silicon Carbide) and GaN(Gallium Nitride) Transistors, are typically realized in high currentdensity, small power dies due to limitations of yield and cost of wafersubstrate.

In order to realize higher power SiC-based modules, a multitude ofparallel connected SiC dies is necessary. Unlike parallel connectedmodules, parallel connected dies constitute a single switch that ideallycommutates the same load current.

SUMMARY OF INVENTION

However, regardless of the type of die used, i.e. diodes orvoltage-driven switch, e.g. MOSFETs (Metal Oxide Semiconductor FieldEffect Transistor), characteristics exist within the dies that limit thebalanced sharing of the load current both statically and dynamically.The incremental addition of each parallel die does not result in fullutilization of the die, and thus, more dies are needed in parallel toachieve a given current rating, thereby increasing the overall costs andphysical surface area of the power module.

Due to variations in the electrical characteristics of power devicesduring manufacturing, the currents are not equally shared across thedies and can be especially unbalanced during switching transitions.Thus, as commutation speeds are increasing with newer technologies, suchas SiC and GaN, this dynamic sharing challenge has only increased inseverity.

One key electrical characteristic for the switching transient is thethreshold voltage of a given voltage-controlled power die herein called‘the die’. For normally-off die, when the voltage across source and gateconnector of a die is below that level, the die channel does notconduct. Above that level, the die starts conducting. When the thresholdvoltages are not perfectly matched across a set of parallel diescontrolled with same gate voltage, the currents are not equally sharedacross these dies during the switching transient. As a result, theswitching losses can significantly differ across parallel dies, leadingto undesired temperature imbalance across dies, and eventually, earlyaging of the most stressed die.

Typically, the number of parallel dies per logically equivalent switchin a multi-die power module is a function of the desired current rating,the peak power dissipation of the multi-die power module package and thethermal rating of the dies within the package. Once the number of diesis set, the actual losses in the multi-die power module are related tothe number N of parallel IGBT or MOSFET dies as:

Pcond(N)∝1/N

Pswitching(N)∝N

Where Pcond(N) is the power when the N dies are conducting andPswitching(N) is the power when the N dies are switching.

Then, the total power is Ptotal(N)=Pcond(N)+Pswitching(N)

In this manner, a given current rating for a multi-die power module hasminimal loss point that is dependent on the number N of dies, and theoperating conditions, i.e. frequency and blocking voltage.

While the conduction losses can be decreased via adding more dies inparallel, i.e. to meet the static current requirements, this increase ofdies results in more parallel capacitances at each node and increasesswitching losses.

Hence, for a given set of dies that meet a static current capability,the switching energy is fixed and the power losses can only be reducedvia lower switching frequencies.

State of the art multi-die power modules can only allow for amodification in gate driving voltage or gate resistance to change thecommutation time and the number of parallel dies largely limits thedynamic performance of the multi-die power module.

Ignoring the reverse recovery of the diode in a complementary switchpair and its influence on the total conducting current, the turn off andturn on times of a voltage-controlled die can essentially be modelled ascapacitor charging event with the current rise time during a turn onevent is as follows:

${tri} = {{Rg} \cdot {Ciss} \cdot {\ln \left( \frac{{Vgs}_{on} - {Vth}}{{Vgs}_{on} - {{gfs}^{- 1}I_{D}}} \right)}}$

Where, ‘Rg’ is the gate resistance, ‘Ciss’ is the input capacitance,Vgs_(on) is the applied gate voltage, ‘Vth’ is the threshold voltage,‘gfs’ is the transconductance of the die and I_(d) is the drain current.

Accordingly, where the plateau voltage (gfs⁻¹Id) is much smaller thanthe applied gate voltage, an increase in current results in anapproximately linear increase in the rise time of the current with asimilar relationship for the current fall time and voltage rise/falltimes.

The example given is in reference to FIGS. 2a and 2 b.

The FIG. 2a is an example of a multi-die power module wherein two diesS1 and S2 are connected in parallel. When the dies are both conducting,the die S1 has a current equal to Id(1−α) and the die S2 has a currentequal to Id(1−α), where ‘α’ is the per-unit difference between themagnitude of commutated current.

Under the case where the plateau voltage is much smaller than theapplied voltage, when one die has a current of 2I_(d) and the other nocurrent, the global switching losses between the two dies areapproximately equal to the case where they both carry the same draincurrent. However, if the input capacitance was to change between the twocases, i.e. reduced in the case where one die is loaded entirely, theswitching losses could actually decrease globally compared to twoequally loaded dies due to a lowering of the current rise time in theactive device.

FIG. 2b shows the currents going through the dies when the dies switchat different timings.

During the time period noted 20, the die S2 is turned ON and during thetime period noted 21, the dies S1 and S2 are turned ON.

Typically, as seen in FIG. 2, if in the case of two parallel MOSFETdies, the input capacitance seen by the gate driver is the sum of bothof the dies, and hence the switching losses are a function of theseparameters given a limited gate supply voltage.

In this case, the two commutating dies, due to differing thresholdvoltages, begin to conduct currents at different times, leading to amismatch of current at time ‘t’, and oscillatory behaviour as thecurrent tries to balance between the two dies. These oscillations thenresult in an increase of the Electro Magnetic Interference.

The present invention aims at enhancing the switching speed of multi-diepower modules and to increase the maximum capability of a multi-diepower module by controlling switching transients for parallel-connecteddevice without need to implement highly dynamic control.

To that end, the present invention concerns a system comprising amulti-die power module composed of dies and a controller receivingplural consecutive input patterns for activating the dies of themulti-die power module, characterized in that the dies are grouped intoplural groups of at least one die and in that the controller comprises:

-   -   means for outputting one gate to source signal for each group of        at least one die, the rising edges and/or falling edges of at        least one gate to source signal being iteratively time shifted        from the rising edge and/or a falling edge of the other gate to        source signals for other groups of dies.

Thus, the commutation current can effectively be concentrated in aselect group of dies or a single die in order to reduce oscillations andreduce the commutation time.

The present invention concerns also a method for controlling theoperation of a multi-die power module composed of groups of diescharacterized in that the method comprises the steps executed by acontroller of:

-   -   receiving plural consecutive input patterns for activating the        dies of the multi-die power module,    -   outputting one gate to source signal for each group of at least        one die, the rising edges and/or falling edges of at least one        gate to source signal being iteratively time shifted from the        rising edge and/or a falling edge of the other gate to source        signals for other groups of dies.

According to a particular feature, the system further comprises meansfor adjusting the number of dies or groups of dies according to currentrequirement and maximum current driving capability of the dies of themulti-die power module.

Thus, the safe operating area of the power module is always ensured.

According to a particular feature, the system comprises further meansfor changing, at each input, patterns for activating the dies of themulti-die power module, of at least one gate to source signal of whichthe rising edge and/or a falling edge is time shifted.

Thus, the time shift can be adapted according to different parametersthat influence the rising and falling time of the commutation current inthe die.

According to a particular feature, the gate to source signals of whichthe rising edge and/or a falling edge are time shifted are changed on around robin basis.

Thus, the individual dies are not overstressed over the lifetime of thepower module.

According to a particular feature, the time shift occurrences are, at aminimum, dependent of the commutations properties of the dies and are atleast ten times smaller than the total conduction time of the die.

Thus, a simple method exists to pre-determine the appropriate time shiftto ensure proper operation without the need of feedback.

The characteristics of the invention will emerge more clearly from areading of the following description of example embodiments, the saiddescription being produced with reference to the accompanying drawings,among which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 represents an example of a system for controlling the operationof a multi-die power module according to the present invention.

FIG. 2a is an example of a multi-die power module wherein two dies areconnected in parallel.

FIG. 2b shows the currents going through the dies when the dies switchat different timings.

FIG. 3 represents an example of an architecture of a controller of thesystem for controlling the operation of a multi-die power moduleaccording to the present invention.

FIG. 4 represents an example of a control of the switching timing of amulti-die power module.

FIG. 5a is an example of a multi-die power module wherein two dies areconnected in parallel and controlled according to the present invention.

FIG. 5b shows the currents going through the dies when the dies switchat different timings according to the present invention.

FIG. 5c is an example of a multi-die power module wherein two dies areconnected in parallel and controlled according to the present invention.

FIG. 5d shows the currents going through the dies when the dies switchat different timings according to the present invention.

FIG. 6 is an example of an algorithm for controlling the switching timeof the dies of a multi-power die module according to the presentinvention.

DESCRIPTION OF EMBODIMENTS

FIG. 1 represents an example of a system for controlling the operationof a multi-die power module according to the present invention.

The system for controlling the operation of the multi-die power module150 uses an open loop mechanism and controls the switching time of thedies in the multi-die power module 150.

The system for controlling the operation of the multi-die power module150 comprises a plurality of gate drivers 102 for providing a drivingsignal to at least one or plural dies 105 of the multi-die power module150.

In the example of FIG. 1, the system for controlling the operation ofthe multi-die power module 150 comprises three gate drivers 102 a to 102c for controlling the operation of three groups of at least one powerdie.

In the example of FIG. 1, each group of at least one power die comprisesone die, respectively noted 105 a to 105 c.

The gate drivers 102 a to 102 receive command signal from a controller104 which is disclosed in reference to FIG. 3.

FIG. 3 represents an example of an architecture of a controller of thesystem for controlling the operation of a multi-die power moduleaccording to the present invention.

The controller 104 has, for example, an architecture based on componentsconnected together by a bus 301 and a processor 300 controlled by theprogram as disclosed in FIG. 6.

The bus 301 links the processor 200 to a read only memory ROM 302, arandom access memory RAM 303 and an input/output interface I/O 305.

The memory 303 contains registers intended to receive variables and theinstructions of the program related to the algorithm as disclosed inFIG. 6.

The processor 300 receives command patterns from a host controllerthrough the input/output interface 305, modifies the rising/falling edgetimes of the signal to be applied by the gate drivers 102 to the dies105 and transfers them to the gate drivers 102 through the input/outputinterface 305.

The input/output interface I/O 205 may be split into two interfaces, onewith the host controller and one with the device for controlling theoperation of a power die 102.

Through the input/output interface 205, the controller 104 receives anactivation or load command from a host controller. The controller 104interprets this activation command and provides synchronized controlover the plurality of dies.

The read only memory 302 contains instructions of the program related tothe algorithm as disclosed in FIG. 6, which are transferred, when thecontroller 104 is powered on, to the random access memory 303.

Any and all steps of the algorithm described hereafter with regard toFIG. 6 may be implemented in software by execution of a set ofinstructions or program by a programmable computing machine, such as aPC (Personal Computer), a DSP (Digital Signal Processor) or amicrocontroller; or else implemented in hardware by a machine or adedicated component, such as an FPGA (Field-Programmable Gate Array) oran ASIC (Application-Specific Integrated Circuit).

In other words, the controller 104 includes circuitry, or a deviceincluding circuitry, causing the controller 104 to perform the steps ofthe algorithm described hereafter with regard to FIG. 6.

The controller 104 may be realized, for example, by a pre-programmedCPLD (Complex Programmable Logic Device).

According to the invention, the dies are grouped into plural groups ofat least one die and the controller comprises:

-   -   means for outputting one gate to source signal for each group of        at least one die, the rising edges and/or falling edges of at        least one gate to source signal being iteratively time shifted        from the rising edge and/or a falling edge of the other gate to        source signals for other groups of dies.

FIG. 4 represents an example of a control of the switching timing of amulti-die power module.

The controller 104 receives command patterns from the host controller.Command patterns are noted 400.

For example, the active time i.e. the high level state, of the controlpatterns are comprised between 2 microseconds to 10 microseconds.

The signal noted 410 is the signal provided to the gate driver 102 a,the signal noted 420 is the signal provided to the gate driver 102 b andthe signal noted 430 is the signal provided to the gate driver 102 c.

According to the invention, the controller 104 delays rising edge times,advances falling edge times on a round trip basis.

For example, at first high level state of the control pattern, thecontroller 104 generates a high level 411 for the signal 410 byadvancing the falling edge time by a predetermined value, the controller104 generates a high level 421 for the signal 420 by delaying the risingedge time by the predetermined value and the controller 104 generates ahigh level 431 for the signal 430 by delaying the rising edge time bythe predetermined value and by advancing the falling edge time by thepredetermined value.

At second high level state of the control pattern, the controller 104generates a high level 412 for the signal 410 by delaying the risingedge time by the predetermined value, the controller 104 generates ahigh level 422 for the signal 420 by delaying the rising edge time bythe predetermined value and by advancing the falling edge time by thepredetermined value and the controller 104 generates a high level 432for the signal 430 by advancing the falling edge time by thepredetermined value.

At third high level state of the control pattern, the controller 104generates a high level 413 for the signal 410 by delaying the risingedge time by the predetermined value and by advancing the falling edgetime by the predetermined value, the controller 104 generates a highlevel 423 for the signal 420 by advancing the falling edge time by thepredetermined value and the controller 104 generates a high level 433for the signal 430 by delaying the rising edge time by the predeterminedvalue.

The round robin cycle is repeated as shown by the high levels 414, 424and 434 which are similar as the ones noted 411, 421 and 431.

The predetermined value is for example between 10 to 50 nanosecondswhich correspond to the switching of the dies 105. It has to be notedhere that this value is based on the transit delay and rise/fall timesof the current in the specific die used in the multi-die power module.The predetermined value is at least ten times smaller than the totalconduction time of each die.

FIGS. 5a and 5c are an example of a multi-die power module wherein twodies are connected in parallel and controlled according to the presentinvention.

In FIG. 5a , the die S1 is conducting and the die S2 is not conducting.In FIG. 5b , the die S2 is conducting and the die S1 is not conducting.

According to the present invention, by delaying or advancing the risingor falling edge time, it is possible to reduce the driving capacitance,as seen by the gate drivers. As one die is left inactive during thecommutation event such that the active die has twice the rated current,the global losses can fall due to a decrease in current rise/fall times.The increase in current does not increase the losses compared to twoconducting dies if the plateau voltage is small compared to the gatevoltage, and thus by decreasing the input capacitance, the losses canfall due to a shortened equivalent commutation time.

Furthermore, a switching loss reduction is also achieved by negating theneed for larger current sharing resistors that are typically added toimprove stability during commutation by increasing the current rise andfall times within the controlled multi-die power module.

An example of how sequencing the dies during commutation can improve thesharing is illustrated in FIGS. 5b and 5 d.

FIGS. 5b and 5d show the currents going through the dies when the diesswitch at different timings according to the present invention.

The FIG. 5b shows the commuting of the die S1 and the FIG. 5d shows thecommuting of the die S2. According to the invention, by sequencing thedies S1 and S2, the currents do not oscillate during turn on, despitehaving different points where the current begins to conduct. Theselatter points therefore remove the need for current balancing resistors,and EMI problems due to oscillations and can equalize the wear on eachdevice.

FIG. 6 is an example of an algorithm for controlling the switching timeof the dies of a multi-power die module according to the presentinvention.

The present algorithm controls a multitude of parallel connected dies bydecreasing the number of dies active during a commutation event andcycles the active dies from one high level command to another. Thepresent algorithm is executed for three groups of dies as an example.The present invention is also applicable for a fewer or greater numberof groups of dies.

Essentially, a number representing the optimal number of parallel diesfor each switching event is pre-loaded into the controller 104.

The controller 104 receives the pulse width modulation command from thehost controller, sets the number of active dies, and then delays theappropriate dies on the rising or turn-on event or advances the dies onthe falling or turn off events to force current into the appropriatedies. The number of dies used in the given switching period is stored,and then for the next switching cycle, the new number of active dies isselected. The inactive dies are sequentially then moved to the next diein each cycle. In this manner, the active dies are cycled through toreduce the loading on the specific dies, caused by the increased currentseen during commutation.

At step S60, the processor 300 determines the minimum number of dies ofeach group of dies. The minimum number is determined according to thecurrent requirement and maximum current driving capability of the diesof the multi-die power module.

At next step S61, the processor 300 detects a high level state of thecontrol pattern through the interface 305.

At next step S62, the processor 300 generates a high level for thesignal intended to the first group of dies comprising the die 105 a byadvancing the falling edge time by the predetermined value, generates ahigh level for the signal intended to the second group of diescomprising the die 105 b by delaying the rising edge time by thepredetermined value and generates a high level for the signal intendedto the first group of dies comprising the die 105 c by delaying therising edge time by the predetermined value and by advancing the fallingedge time by the predetermined value.

At next step S63, the processor 300 detects a high level state of thecontrol pattern through the interface 305.

At next step S64, the processor 300 generates a high level for thesignal intended to the first group of dies comprising the die 105 a bydelaying the rising edge time by the predetermined value, generates ahigh level for the signal intended to the second group of diescomprising the die 105 b by delaying the rising edge time by thepredetermined value and by advancing the falling edge time by thepredetermined value and generates a high level for the signal intendedto the first group of dies comprising the die 105 c by advancing thefalling edge time by the predetermined value.

At next step S65, the processor 300 detects a high level state of thecontrol pattern through the interface 305.

At next step S66, the processor 300 generates a high level for thesignal intended to the first group of dies comprising the die 105 a bydelaying the rising edge time by the predetermined value and byadvancing the falling edge time by the predetermined value, generates ahigh level for the signal intended to the second group of diescomprising the die 105 b by advancing the falling edge time by thepredetermined value and generates a high level for the signal intendedto the first group of dies comprising the die 105 c by delaying therising edge time by the predetermined value.

After that the processor 300 returns to step S61.

Naturally, many modifications can be made to the embodiments of theinvention described above without departing from the scope of thepresent invention.

1-10. (canceled)
 11. System comprising a multi-die power module composedof dies and a controller receiving plural consecutive input patterns foractivating the dies of the multi-die power module, the input patternsbeing composed of rising edge and falling edges, characterized in thatthe dies are grouped into a first a second and a third groups of atleast one die and in that the controller comprises: means for advancingthe falling edge time of the gate signal for the first group of at leastone die by a predetermined value, means for delaying the rising edgetime of the gate signal for the second group of at least one die by thepredetermined value, means for delaying the rising edge time of the gatesignal for the third group of at least one die by the predeterminedvalue and for advancing the falling edge time of the gate signal for thethird group of at least one die by the predetermined value.
 12. Systemaccording to claim 11, characterized in that the system furthercomprises means for adjusting the number of dies or groups of diesaccording to current requirement and maximum current driving capabilityof the dies of the multi-die power module.
 13. System according to claim11, characterized in that the system comprises further means forchanging, at each input patterns for activating the dies of themulti-die power module, the at least one gate to source signal of whichthe rising edge and/or a falling edge is time shifted.
 14. Systemaccording to claim 13, characterized in that the gate to source signalsof which the rising edge and/or a falling edge are time shifted arechanged on a round robin basis.
 15. System according to claim 11,characterized in that the time shift occurrences are, at a minimum,dependent of the commutations properties of the dies and are at leastten times smaller than the total conduction time of the die.
 16. Methodfor controlling the operation of a multi-die power module composed ofgroups of dies, characterized in that the dies are grouped into a firsta second and a third groups of at least one die and in that the methodcomprises the steps executed by a controller of: receiving pluralconsecutive input patterns for activating the dies of the multi-diepower module, wherein the input patterns being composed of rising edgeand falling edges, advancing the falling edge time of the gate signalfor the first group of at least one die by a predetermined value,delaying the rising edge time of the gate signal for the second group ofat least one die by the predetermined value, delaying the rising edgetime of the gate signal for the third group of at least one die by thepredetermined value and for advancing the falling edge time of the gatesignal for the third group of at least one die by the predeterminedvalue.
 17. Method according to claim 16, characterized in that themethod further comprises the step of adjusting the number of dies of theclusters of dies according to current requirement and maximum currentdriving capability of the dies of the multi-die power module.
 18. Methodaccording to claim 16, characterized in that the method comprisesfurther step of changing, at each input patterns for activating the diesof the multi-die power module, the at least one gate to source signal ofwhich the rising edge and/or a falling edge is time shifted.
 19. Methodaccording to claim 18, characterized in that the gate to source signalsof which the rising edge and/or a falling edge are time shifted arechanged on a round robin basis.
 20. Method according to claim 16,characterized in that the time shift occurrences are, at a minimum,dependent of the commutations properties of the dies and are at leastten times smaller than the total conduction time of the die.